Outback Flexmax 60 Charge Controller

Outback Flexmax 60 Charge Controller 12 / 24 / 48 VDC Mid Range Battery Charger

Outback Flexmax 60 charge controllers is solid-state electronic device that, when sized properly, can be used in nearly every solar and wind energy system that uses batteries. The Charge controllers Blue Pacific Solar sells employ the latest in power electronics to regulate the battery charge by controlling the charging voltage and current from a solar panel array. Charge controllers regulate the charge of the battery, but also prevent the battery from being over discharged which can damage the battery bank.

Outback charge controller uses multiple stages of control to regulate different voltage and current levels. The voltage and current of a battery varies over the different stages of battery charge. Though the amount can vary, the bulk charge usually is approximately 80%, the absorption charge is 10% with the float charge representing the balance of the battery charging process.

The bulk charging stage of the Outback charge controller process is the first stage to used to bring the battery depth of discharge (DOD) back to 100%. The bulk charge stage happens first in in the morning after the batteries DOD has drained down since sunset the previous day. The bulk charging stage pushes as many amps into the battery bank as possible from the solar panels and gets the voltage up in the process. The effect of a charge controller is not unlike trying to fill a glass of water from a faucet. You first turn the faucet on full while the glass if filling, then slowly taper off the pressure until the glass is full. When the battery bank reaches a predetermined level known as the bulk voltage set-point, the charge is then substantially slowed. Because the bulk voltage set point is determined by the type of battery you are using, many charge controllers have to be pre-set to the type of battery which will dictate the rate of charge.

The second state of charge the Outback charge controller employs is the absorption stage. After a battery system has been brought up to the bulk voltage set point, the charge controller slows down the charge rate because the battery bank cannot accept the same rapid charging pace without overheating and damaging the battery bank. At the absorption stage a battery bank is only about 80% full. The absorption charge is the function level in the process that tops off the battery bank. During the absorption stage, the charge controller holds the battery volts constant and reduces the amount of current sent into the battery. When the absorption stage is complete, the battery bank is fully charges.

The final step the Outback Flexmax 60 charge controller performs is the float charge. Typically a charge controller enters into a float charge state when the other charge levels of the battery bank has been achieved. When the number of peak sun hours is limited, a solar charge controller may not be able to get the battery bank back to the float stage before the next cycle begins.

IMPORTANT SAFETY INSTRUCTIONS: Outback Charge Controller. (OK, here is the scary legal disclaimer.) It is the responsibility of the purchaser to ensure that all products are installed and operated in accordance with local and national building codes as specific by the NEC (National Electric Code), UBC (Uniform Building Code) or IBC (International Building Code) and local utility company policy. This product is designed for indoor or protected compartment installations. DO NOT expose the Outback to rain, snow, moisture or liquids of any type. Use insulated tools to reduce the chance of electrical shock or accidental short circuits. Remove all jewelry such as rings, watches, bracelets, etc when installing the Outback Charge Controller or any other electronic gear. Always disconnect the batteries or energy source prior to installation or performing maintenance on the Outback charge controller inverter. Live power may be present at more than one point since an inverter utilizes both batteries and AC electricity. Turning off the Outback Charge Controller may not reduce that risk. Always verify proper wiring prior to starting the inverter. Do not operate the Outback charge controller if it has been damaged. Always read and follow the manufactures installation and operating instructions for the Outback Flexmax 60 charge controller prior to installation and operation.